Golden Buzzaround Carry On User manual

Buzzaround Carry On
Service Guide
This Service Guide contains:
Troubleshooting
Replacement Instructions
Multi-meter Instructions
Model: GB120

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Table of Contents
Nomenclature and Contact Information.........................................................................................4
ABOUT THE BUZZAROUND CARRY ON SERVICE GUIDE.......................................................5
Buzzaround Carry On Components..........................................................................................5-10
Wiring Diagram............................................................................................................................11
SCENARIO 1: Turn the key to the on position and no power......................................................12
SCENARIO 2: Battery Pack will not charge.................................................................................13
BEEP/FLASH CODES............................................................................................................14-17
BEEP/FLASH CODE #1 - Battery Pack Low (Scooter may drive slowly)....................................14
BEEP/FLASH CODE #2 - Battery Pack Low (Scooter will not operate)......................................14
BEEP/FLASH CODE #3 - High Battery Voltage..........................................................................14
BEEP/FLASH CODE #4 - Current Limit Timeout.........................................................................14
BEEP/FLASH CODE #5 - Brake Fault.........................................................................................15
BEEP/FLASH CODE #6 - Paddle Fault (out of neutral)...............................................................15
BEEP/FLASH CODE #7 - Paddle Fault/Speed Control Fault (voltage error).........................16-17
BEEP/FLASH CODE #8 - Motor Voltage Fault (Open/Shorted)..................................................17
BEEP/FLASH CODE #9 - Controller Fault...................................................................................17
BUZZAROUND CARRY ON REPLACEMENT INSTRUCTIONS...........................................18-23
Drive Wheel..................................................................................................................................18
Anti Tip……..................................................................................................................................18
Throttle Pot...................................................................................................................................18
Battery Pack.................................................................................................................................19
Fuses......................................................................................................................................19-20
Controller......................................................................................................................................20
Dash and Dash Components………………………………....………………………………………..21
Upper Main Harness....................................................................................................................21
Transaxle Assembly.....................................................................................................................22
Lower Main Harness……………………………………………………………………………..……...22
Steering Assembly………………………………………………………………………………………23
Tiller Shock………………………………………………………..……………………………………..23
APPENDIX A - HOW TO USE A VOLTMETER...........................................................................24
APPENDIX B - HOW TO USE AN OHM METER........................................................................25

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BUZZAROUND CARRY ON NOMENCLATURE
Figure 1. Buzzaround Carry On (Model GB120)
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10
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1 - Seat
2 - Arm Assembly
3 - Seat Plate
4 - Seat Pedestal
5 - Tiller Assembly
6 - Lithium Ion Battery Pack
7 - Drive Train
(Transaxle, Motor, Brake)
8 - Controller (located under cover)
9 - Steering Assembly
10 - Front Wheel
11 - Rear Wheel (Drive)
12 - Freewheel Switch
13 - Dash (Upper/Lower)
14 - USB Board (Inside)
15 - Bottle Holder
16 - Hand Grip
17 - Tiller Adjustment Lever
18 - Paddle (Throttle Lever)
19 - LED Head Light
20 - LED Tail Light
21 - Deck (Upper/Lower)
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Contact Information
Golden Technologies
401 Bridge Street
Old Forge, PA 18518
Toll-free: 800-624-6374
Mobility Tech: x501
Lift Chair: x502
VA Tech: x505
Fax: [phone]
Email: [email protected]
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This service guide provides you with the information necessary to troubleshoot the Golden Technologies
Buzzaround Carry On GB120. The troubleshooting scenarios in this manual consist of procedures that
enable you to systematically trace and correct faults in the system. Appendices A and B include instructions
on how to measure voltage and continuity with a multimeter.
Before troubleshooting, check the following:
 Make sure the battery pack is seated securely.
 Visually check terminals for corrosion. Check wires for missing insulation.
 Make sure there are no blown fuses.
 Make sure that the battery pack is fully charged and in good working order. When possible, keep a
known good battery pack in your shop at all times. The Buzzaround Carry On uses (1) 15AH or
6.5AH Lithium Ion battery pack. Problems that surface during troubleshooting are often due to the
fact that the battery pack is not fully charged or can not hold a charge.
 Make sure that the electrical connections are secure. Unplug the connectors and make sure all the
pins in the connectors are seated securely. If necessary, push any unseated pins back into their
connector housings to securely seat them.
If you get to a point during troubleshooting where you cannot continue, call
Technical Support at 800-624-6374.
BUZZAROUND CARRY ON COMPONENTS
The Buzzaround Carry On is a battery-operated scooter with a controller that monitors the system and
flashes/beeps when it detects a fault in the system. The Buzzaround Carry On was designed to operate within
a range of between 22V– 30.8V (Volts) of direct current (DC).
The Buzzaround Carry On control system is made up of the components listed below.
Each of these components is designated by its assigned number. Refer to the wiring diagram on page 11.
• 24V Lithium Ion Battery Pack - #1
• Battery Harnesses - #2
• Motor Harness - #3
• Dynamics R-Series Controller - #4
• Main Harness - upper/lower - #5
• Motor/Brake Assembly - NA
• Dash (Upper/Lower) - NA, see console board- #7
Note: includes Throttle Pot- #8, Speed Pot - #9, Key Switch - #10, Horn Button, Light Switch, and
Battery Meter
• XLR Charging Ports - One located on the tiller and one on the bottom side of the battery pack. - NA
• USB Charging Ports - One located on the tiller and one on the bottom side of the battery pack. - NA
Note: See Charger Harness - #11
• Off-Board Battery Charger - NA
Note: NA - Not Applicable
Parts and service must be authorized by the Golden Technologies Service
Department. Unauthorized parts or service may void the warranty. For more information, contact the
Golden Technologies Service Department at 800-624-6374 or [email protected].

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Component: 1-24VDC Lithium Ion Battery Pack (15AH or 6.5AH) - #1
Location: Center of the upper deck. See figure 2.
Function: Supply 24-29VDC to the motor and/or accessories.
Connections: Connected by two spr ing loaded connectors at the r ear
of the battery pack and a push-button latch at the front of the battery pack.
Failure Signs: Batter ies dr ain quickly. Scooter r uns slowly or not at all.
Batteries will not charge, but charger is working properly. Beep Code #1 or #2.
Tests: Fully charge the batter y pack first and load test. Make sur e the contacts
are not corroded.
Expected Reading: 24-29VDC when fully charged.
Serviceable: Replace batter y pack as necessary.
Component: Battery Harness - #2 Figure 2. Lithium Ion Battery Pack
Location: Inside the plastic upper/lower body halves.
Function: Connects the batter y (1) to the contr oller (4), and
the control board inside the scooter deck.
Provides short circuit protection through a 35-amp inline fuse,
located inside the controller cover.
Connections: Connected to the batter y (Bat -) and (Bat +),
controller (Bat -) and (Bat +), control board, and battery fuse.
Refer to the wiring diagram on page 11.
Failure Signs: Open fuse, cor r oded wir es, poor
connections, and poor spring tension can cause the battery
voltage (24-29 volts) not to be supplied to the entire electrical
system.
Make sure the fuse is good, and all connections are good.
Note: Battery pack will not charge if the inline fuse is blown.
Tests: Test the fuse for continuity. Test the har ness for
continuity. See figure 3. Refer to the wiring diagram on
page 11.
Expected Readings: Less than 10 ohms.
Serviceable: Replace the har ness as necessar y.
Replace inline fuse with exact type and rating. Refer to the
wiring diagram on page 11. Figure 3. Battery Harness
Component: Motor Harness - #3
Location: Rear of the scooter – Inside the plastic
upper/lower body halves. See figure 4. Refer to the
wiring diagram on page 11.
Function: Supplies 24-29 volts from the controller to
the motor.
Connections: Controller (M+) and (M-) and the motor.
See figure 4. Refer to the wir ing diagram on page 11.
Failure Signs: Scooter will not run. The motor is not
receiving the correct 24-29 volt battery voltage from the
controller.
Tests: Test har nesses for continuity. Check connectors.
Make sure the contacts are not corroded and are seated
properly.
Expected Readings: Continuity (less than 10 ohms). Figure 4. Motor Harness (hard wired into motor)
Serviceable: Replace as necessar y.

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Figure 5. Controller
Component: Contr oller - #4
Location: Mounted inside the deck under the removable contr oller cover. See figure 5.
Function: Contr ols and monitors the system. Uses a ser ies of beeps/flashes when something in the system is out
of range.
Connections: Connected to the main harness (5), char ger & inhibit, br ake, motor (M-M+), battery (B-B+). See
figure 3. Refer to the wiring diagram on page 11.
Failure Signs: Beep Code #9. No power to the control panel or the motor .
Tests: Test for voltage coming into and out of the controller.
Expected readings: Battery voltage (24-29VDC).
Serviceable: Replace as necessar y.
Component: Main Har ness - #5
Location: Inside the dash and the plastic upper/lower body halves. See figures 5 and 6. Refer to the wiring
diagram on page 11.
Function: Provides connectivity for the tiller components and the contr oller.
Connections: Connected to the contr oller , and contr ol panel. Refer to the wiring diagr am on page 11.
Failure Signs: Scooter will not run.
Tests: Test for voltage and continuity. Check connectors. Make sur e the pins ar e not corr oded and are seated
properly.
Expected readings: Battery voltage (24-29VDC). Continuity (less than 10 ohms).
Serviceable: Replace as necessar y.
Figure 6. Main Harness (Shown Separated)
Main
Harness
Charger & inhibit
Brake
M- M+
Bat- Bat+
Fuse
Spare Fuse
UPPER HARNESSLOWER HARNESS

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Component: Brake Harness - #6
Location: Fr om the brake to the contr ol board. See figure 7.
Function: Provides connectivity between the br ake and the
freewheel switch.
Connections: CN4 on the contr ol boar d. Refer to the wiring
diagram on page 11.
Failure Signs: Scooter faults and will not move.
Tests: Test for voltage and continuity. Check connectors.
Make sure the pins are not corroded and are seated properly.
Expected readings: Continuity (less than 10 ohms).
Serviceable: Replace as necessar y.
Component: Console Board - #7 Figure 7. Control Board
Location: Mounted inside the dash. See figure 8.
Function: Provides connectivity for the main harness,
key switch, speed pot, throttle pot, battery meter, on/off
switch, horn, and horn button.
Connections: Connections CN1 - CN8. Refer to the
wiring diagram on page 11.
Failure Signs: Scooter faults, will r un slowly or
not at all.
Meter and/or horn does not function.
Tests: Test for voltage and continuity. Check
connectors.
Make sure the contacts are not corroded.
Expected readings: Continuity (less than 10 ohms).
Serviceable: Replace as necessar y. Figure 8. Console Board
Component: Throttle Pot (Potentiometer) - #8
Location: Below the control panel. See figure 9.
Function: The thr ottle pot uses variable r esistance
to control speed and direction of travel by varying voltage.
Connections: CN7 on the console board. Refer to the wiring
diagram on page 11.
Failure Signs: Beep Codes #6 and #7.
Tests: Test resistance across pins 1, 2, and 3 on the thr ottle pot.
Expected readings: Depends on dir ection of deflection.
Serviceable: Replace as necessar y.
Component: Speed Pot (Potentiometer ) - #9
Location: Mounted on the control panel. See figure 10.
Function: The speed pot uses var iable resistance to control
the speed of the scooter.
Connections: CN8 on the console board. Refer to the wiring Figure 9. Throttle Potentiometer
diagram on page 11.
Failure Signs: Beep Code #7
Tests: Call Tech Support
Expected readings: Depends on speed pot position.
Serviceable: Yes. Replace the speed pot.
Figure 10. Speed Pot
CN4

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Component: Key Switch - #10
Location: Mounted on the control panel. See figure 11.
Function: Completes the cir cuit to pr ovide power to
the motor.
Connections: CN2 on the console board. Refer to the
wiring diagram on page 11.
Failure Signs: No power when the key is in the
“ON” position.
Tests: Continuity when the key is in the “ON” position. Figure 11. Key switch
Make sure the connector pins are seated properly.
Expected readings: Less than 10 ohms.
Serviceable: Yes. Replace the key switch.
Component: Charger Har ness - #11
Location: Inside of the tiller below the contr ol panel.
See figure 12.
Function: Supplies voltage to the USB port and allows the
battery pack to be charged through the tiller XLR port.
Connections: Connected to the USB boar d, tiller fuse, and
tiller XLR charging port. See figure 12. Refer to the wiring
diagram on page 11.
Failure Signs: Batter y pack will not char ge thr ough the tiller
XLR port, and USB port does not function.
Tests: Test for voltage and continuity. Check connectors.
Make sure the pins are not corroded and are seated properly.
Expected readings: Battery voltage (24-29VDC).
Continuity (less than 10 ohms).
Serviceable: Replace the har ness as necessar y.
Figure 12. Charger Harness
Component: Motor/Brake Assembly - NA
Location: Mounted on the transaxle. See figure 13.
Function: Drives the scooter .
Connections: Connected to the contr oller ,
control board, and the transaxle.
Refer to the wiring diagram on page 11.
Failure Signs: Scooter r uns slowly or not at all.
Tests: Test for internal r esistance in motor . Test
motor wires for continuity. See Beep Codes #5 and #8.
Expected readings: Internal motor resistance is
0.8 ohms – 1.5 ohms. Brake resistance is
45 ohms – 52 ohms.
Serviceable: Replace the complete tr ansaxle assembly.
Component: Brake - NA
Location: Mounted on the end of the motor. Figure 13. Complete Transaxle Assembly
See figure 13.
Function: Keeps the motor from moving when
the power is off.
Connections: Connected to CN4 on the contr ol boar d through the br ake harness (6). Refer to the wiring
diagram on page 11.
Failure Signs: Scooter r uns slowly or not at all.
Tests: Test for internal r esistance. See Beep Code #5.
Expected readings: Brake resistance is 45 ohms – 52 ohms.
Serviceable: Replace the complete tr ansaxle assembly.
Transaxle
Motor Brake

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Component: Off-Board Charger - NA, (Not shown)
Location: Stor ed inside a pouch on the seatback.
Function: Char ges the batter y pack.
Connections: Connects to the XLR char ger port on the tiller or back side of the batter y pack. Refer to the
wiring diagram on page 11.
Failure Signs: Char ger power LED does not go on. Batteries will not char ge.
Tests: Measure voltage across (B-) a black wire and (B+) a red wire on the controller (4) battery terminals.
While observing the voltage reading, plug the charger into the wall outlet and make sure the voltage reading increases.
Expected readings: Battery voltage (24-29VDC) first, approximately 29 volts when fully charged. Also, refer to the
charger test on page 13. Test charger harness and fuse for continuity.
Serviceable: Replace if necessar y.
Only use the charge that was supplied with the scooter. The charger was specifically
designed and tested for the product it came with.